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Egyptair CFM56-7B HPC Module HPC Shroud Slab Headed Anti-rotation Pin Liberations CFM, CFM56, LEAP and
Egyptair CFM56-7B HPC Module HPC Shroud Slab Headed Anti-rotation Pin Liberations CFM, CFM56, LEAP and
Egyptair CFM56-7B HPC Module HPC Shroud Slab Headed Anti-rotation Pin Liberations CFM, CFM56, LEAP and

Egyptair CFM56-7B

HPC Module

HPC Shroud Slab Headed Anti-rotation Pin Liberations

CFM, CFM56, LEAP and the CFM logo are trademarks of CFM International, a 50/50 joint company between Snecma (Safran group) and GE. The information in this document is CFM Proprietary Information and is disclosed in confidence. It is the property of CFM International and its parent companies, and shall not be used, disclosed to others or reproduced without the express written consent of CFM. If consent is given for reproduction in whole or in part, this notice shall appear in any such reproduction in whole or in part. The information contained in this document may also be controlled by the U.S. and French export control laws. Unauthorized export or re-export is prohibited.

Background

Background • Slab head pin introduced to address HPC honeycomb seal rotation and avoid radial retention

Slab head pin introduced to address HPC honeycomb seal rotation and avoid radial retention pin liberations

Introduced Jul 2007 in production

SB 72-0678 (5B), 72-0673 (7B) & 72-0645 (5C)

Anti-Rotation pins located in 2 shrouds per stage (3 and 9 o’clock positions)

38 /

Radial Retention Pins (holds shroud to vane)

Anti-rotation pin designs

New design

Slab head pin design

New design Slab head pin design
Anti-rotation pin designs New design Slab head pin design Original design Headed pin Headed pin Honeycomb
Anti-rotation pin designs New design Slab head pin design Original design Headed pin Headed pin Honeycomb

Original design

designs New design Slab head pin design Original design Headed pin Headed pin Honeycomb Honeycomb seal
Headed pin Headed pin
Headed pin
Headed pin
Honeycomb Honeycomb seal seal
Honeycomb
Honeycomb
seal
seal

Anti-Rotation Pins (prevents seal rotation)

seal seal Anti-Rotation Pins (prevents seal rotation) CFM Proprietary Information subject to restrictions on the

CFM Proprietary Information subject to restrictions on the cover

seal seal Anti-Rotation Pins (prevents seal rotation) CFM Proprietary Information subject to restrictions on the cover
seal seal Anti-Rotation Pins (prevents seal rotation) CFM Proprietary Information subject to restrictions on the cover
seal seal Anti-Rotation Pins (prevents seal rotation) CFM Proprietary Information subject to restrictions on the cover

Slab Head Anti-Rotation Pin Experience

32 slab head anti-rotation pin liberations reported (across all engine models)

pin liberations reported (across all engine models) • CFM56-5C/P (4 liberations) & CFM56-5C (2

CFM56-5C/P (4 liberations) & CFM56-5C (2 liberations) also effected

15 of 32 liberations caused engine removal (HPC blade damage found at routine BSI)

3 liberations resulted in recoverable engine stall

Liberations occurred with both composite or metallic/hybrid bushing system and on production and overhauled engines

• No engines liberated both 3 and 9 o’clock pins which would allow seals to rotate leading to radial retention pin liberation

Liberated pin can damage HPC stage 4-9 blades, stage 3 disk and/or 4-9 spool

Composite bushing system

stage 3 disk and/or 4-9 spool Composite bushing system Metallic bushing system Blade and spool damage

Metallic bushing system

4-9 spool Composite bushing system Metallic bushing system Blade and spool damage 39 / CFM Proprietary

Blade and spool damage

system Metallic bushing system Blade and spool damage 39 / CFM Proprietary Information subject to restrictions

39 /

CFM Proprietary Information subject to restrictions on the cover

Metallic bushing system Blade and spool damage 39 / CFM Proprietary Information subject to restrictions on
Metallic bushing system Blade and spool damage 39 / CFM Proprietary Information subject to restrictions on
Metallic bushing system Blade and spool damage 39 / CFM Proprietary Information subject to restrictions on

Failure mode definitions and occurrences by configuration

Failure mode definitions and occurrences by configuration failure mode description 1 J-hook wear through due to
failure mode

failure mode

description

1

J-hook wear through due to RTS contact leading to retention pin liberation

2

honeycomb seal rotation leading to retention pin, seal or bushing liberation

3

retention pin liberation forward through shroud

seal or bushing liberation 3 retention pin liberation forward through shroud 4 liberation of anti-rotation pin

4

liberation of anti-rotation pin

through shroud 4 liberation of anti-rotation pin occurance rate operational event estimated # engines (5A,
through shroud 4 liberation of anti-rotation pin occurance rate operational event estimated # engines (5A,

occurance rate

occurance rate operational event

operational event

occurance rate operational event
occurance rate operational event
of anti-rotation pin occurance rate operational event estimated # engines (5A, 5B, 5C, 7B) configuration intro
of anti-rotation pin occurance rate operational event estimated # engines (5A, 5B, 5C, 7B) configuration intro
of anti-rotation pin occurance rate operational event estimated # engines (5A, 5B, 5C, 7B) configuration intro
of anti-rotation pin occurance rate operational event estimated # engines (5A, 5B, 5C, 7B) configuration intro
of anti-rotation pin occurance rate operational event estimated # engines (5A, 5B, 5C, 7B) configuration intro
of anti-rotation pin occurance rate operational event estimated # engines (5A, 5B, 5C, 7B) configuration intro
of anti-rotation pin occurance rate operational event estimated # engines (5A, 5B, 5C, 7B) configuration intro
of anti-rotation pin occurance rate operational event estimated # engines (5A, 5B, 5C, 7B) configuration intro

estimated # engines (5A, 5B, 5C, 7B)

operational event estimated # engines (5A, 5B, 5C, 7B) configuration intro date production overhaul

configuration

intro date

production

overhaul

composite bushing with round anti-

rotation pin

full metallic bushing system with

round anti-rotation pin

hybrid bushing system with round

anti-rotation pin

composite bushing with headed

anti-rotation pin and wide S3 slot

hybrid bushing system with headed

anti-rotation pin and wide slot

composite bushing with headed

anti-rotation pin and narrow slot

hybrid bushing system with headed

anti-rotation pin and narrow slot

EIS

1639

523

Apr-06

801

0

Apr-07

248

523

Jul-07

0

975

Jul-07

3130

975

Jun-10

0

2787

Jun-10

5127

2787

975 Jun-10 0 2787 Jun-10 5127 2787 total failure mode # occurances per engine IFSD
975 Jun-10 0 2787 Jun-10 5127 2787 total failure mode # occurances per engine IFSD

total

failure mode

# occurances

per engine

IFSD

stall

UER

shop

finding

 

1 15

 

0.69%

3

6

6

0

2 27

 

1.25%

4

17

4

2

2162

3 4

2162 3 4 0.19% 1 2 1 0

0.19%

1

2

1

0

4 7

 

0.32%

1

3

2

1

1 0

0.00%

0

0

0

0

2 0

2 0 0.00% 0 0 0 0

0.00%

0

0

0

0

801

3 1

 

0.12%

0

0

0

1

4 0

 

0.00%

0

0

0

0

1 0

0.00%

0

0

0

0

2 0

 

0.00%

0

0

0

0

771

3 0

 

0.00%

0

0

0

0

4 0

 

0.00%

0

0

0

0

1 0

0.00%

0

0

0

0

2 0

 

0.00%

0

0

0

0

975

3 0

 

0.00%

0

0

0

0

4

16

1.64%

0

1

4

11

1 0

 

0.00%

0

0

0

0

2 0

 

0.00%

0

0

0

0

4105

3 0

 

0.00%

0

0

0

0

4

16

0.39%

0

2

8

6

1 0

 

0.00%

0

0

0

0

2 0

 

0.00%

0

0

0

0

2787

3 0

 

0.00%

0

0

0

0

4 0

 

0.00%

0

0

0

0

1 0

1 0 0.00% 0 0 0 0

0.00%

0

0

0

0

2 2

 

0.03%

0

0

1

1

7914

3 0

 

0.00%

0

0

0

0

4 0

 

0.00%

0

0

0

0

40 /

CFM Proprietary Information subject to restrictions on the cover

High rates of operational

events led to

RTS contact

on-wing

inspection

program

Only 3 anti-

rotation pin

liberations

have resulted

in recoverable

engine stall

on-wing inspection program Only 3 anti- rotation pin liberations have resulted in recoverable engine stall
on-wing inspection program Only 3 anti- rotation pin liberations have resulted in recoverable engine stall
on-wing inspection program Only 3 anti- rotation pin liberations have resulted in recoverable engine stall

Stage 3 headed anti-rotation pin liberation mechanism

Stage 3 headed anti-rotation pin liberation mechanism • Seal slides circumferentially and contacts the side of

Seal slides circumferentially and contacts the side of the pin

Causes pin head to rotate until it contacts the side of the shroud slot

Concurrent shroud rail wear allows seal to move radial inward

41 /

Pin wear from seal Seal movement due to rail wear Pin head rotation and contact
Pin wear
from seal
Seal movement
due to rail wear
Pin head
rotation and
contact
Dim W

Shroud rail wear from seal contact

CFM Proprietary Information subject to restrictions on the cover

and contact Dim W Shroud rail wear from seal contact CFM Proprietary Information subject to restrictions
and contact Dim W Shroud rail wear from seal contact CFM Proprietary Information subject to restrictions
and contact Dim W Shroud rail wear from seal contact CFM Proprietary Information subject to restrictions

Stage 3 headed anti-rotation pin liberation mechanism

Stage 3 headed anti-rotation pin liberation mechanism • Pin head can rotate 90 degrees past the

Pin head can rotate 90 degrees past the corner of the shroud

During rotation the pin head slides up the ramp in the shroud

Causes the pin to move axially away from the shroud

Once rotated 90 degrees pin head no longer retained by seal

Shroud rail wear from seal contact Corner of rotated pin wears into shroud rail forming
Shroud rail wear
from seal contact
Corner of rotated pin wears
into shroud rail forming a
ramp
of rotated pin wears into shroud rail forming a ramp Pin wear into bore on opposing

Pin wear into bore on opposing side

created during

rotation

wear into bore on opposing side created during rotation On-wing photo showing fully rotated and partially
wear into bore on opposing side created during rotation On-wing photo showing fully rotated and partially

On-wing photo showing fully rotated and partially disengaged pin

42 /

CFM Proprietary Information subject to restrictions on the cover

showing fully rotated and partially disengaged pin 42 / CFM Proprietary Information subject to restrictions on
showing fully rotated and partially disengaged pin 42 / CFM Proprietary Information subject to restrictions on
showing fully rotated and partially disengaged pin 42 / CFM Proprietary Information subject to restrictions on

Stg 3 narrow versus wide slot shroud geometry

Narrow slot shroud introduced to limit pin head rotation

Improved geometry should eliminate or significantly lower risk of liberation

should eliminate or significantly lower risk of liberation • With narrow slot shroud W (worst case)

With narrow slot shroud W (worst case) now greater than stage 2 which has never

liberated

All liberations have occurred with wide slot shrouds

• All liberations have occurred with wide slot shrouds 43 / CFM Proprietary Information subject to

43 /

CFM Proprietary Information subject to restrictions on the cover

liberations have occurred with wide slot shrouds 43 / CFM Proprietary Information subject to restrictions on
liberations have occurred with wide slot shrouds 43 / CFM Proprietary Information subject to restrictions on
liberations have occurred with wide slot shrouds 43 / CFM Proprietary Information subject to restrictions on

Narrow slot introduction

Narrow slot introduction 44 • • / Part number of shroud not changed with slot width

44

/

Part number of shroud not changed with slot width optimization

Introduction determined by confirmation of slot width at subsequent shop visit

Production

Wide slot installed for engines manufactured between July 2007 and June 2010 (3714 engines) ( MSR have 21 engines installed)

Overhaul

Wide slot installed for engines overhauled between Jan 2008 and June 2010 (1949 engines)

CFM56-7B delivery status (Production)

7 6 (Wide Slot Installed) 5 4 3 2 1 0 2006 2006 2006 2007
7
6
(Wide Slot Installed)
5
4
3
2
1
0
2006
2006
2006
2007
2007
2008
2009
2009
2009
2009
2009
2010
2010
2010
2010
2011
2012
2012
2012
2012
2012
oct
nov
déc
sept
nov
août
févr
mars
août
sept
oct
sept
oct
nov
déc
juin
févr
mars
avr
juil
sept
2006
2007
2008
2009
2010
2011
2012
7B26
2
1
2
7B26/3
2
2
2
2
2
2
6
3
2
2
2
2
3
7B26E
2
1
1
2
2
Nbr of engines

CFM Proprietary Information subject to restrictions on the cover

3 2 2 2 2 3 7B26E 2 1 1 2 2 Nbr of engines CFM
3 2 2 2 2 3 7B26E 2 1 1 2 2 Nbr of engines CFM
3 2 2 2 2 3 7B26E 2 1 1 2 2 Nbr of engines CFM

Stg 3 narrow versus wide slot shroud field experience

Stg 3 narrow versus wide slot shroud field experience Wide slot shroud CFM56-7B27/3 Narrow slot shroud

Wide slot shroud

CFM56-7B27/3

Narrow slot shroud

CFM56-7B27/3

slot shroud CFM56-7B27/3 Narrow slot shroud CFM56-7B27/3 45 Dimension W increased with narrow slot shroud which
slot shroud CFM56-7B27/3 Narrow slot shroud CFM56-7B27/3 45 Dimension W increased with narrow slot shroud which

45

Dimension W increased with narrow slot shroud which increases contact area and limits pin rotation
Dimension W increased with narrow slot shroud
which increases contact area and limits pin rotation
/
CFM Proprietary Information subject to restrictions on the cover
which increases contact area and limits pin rotation / CFM Proprietary Information subject to restrictions on
which increases contact area and limits pin rotation / CFM Proprietary Information subject to restrictions on
which increases contact area and limits pin rotation / CFM Proprietary Information subject to restrictions on

Narrow versus Wide slot histogram

Narrow versus Wide slot histogram Wide slot = 5663 engines Narrow slot = 10825 engines Typical
Wide slot = 5663 engines Narrow slot = 10825 engines Typical time of wide slot
Wide slot = 5663 engines
Narrow slot = 10825 engines
Typical time
of wide slot
composite
liberation
Typical time of
wide slot
metallic/hybrid
liberation

46 /

CFM Proprietary Information subject to restrictions on the cover

TSN or TSSV

wide slot metallic/hybrid liberation 46 / CFM Proprietary Information subject to restrictions on the cover TSN
wide slot metallic/hybrid liberation 46 / CFM Proprietary Information subject to restrictions on the cover TSN
wide slot metallic/hybrid liberation 46 / CFM Proprietary Information subject to restrictions on the cover TSN

Comparison with Radial Retention Pin Liberations

Comparison with Radial Retention Pin Liberations • Radial retention pin likely to liberate if both 3

Radial retention pin likely to liberate if both 3 and 9 o’clock slab head anti-rotation pins liberate

Radial retention pin liberations

more severe due to size of pin

Results in more extensive HPC blade damage

41 radial retention pin liberations reported across CFM engine models

Due to rotor to stator contact with

composite bushings or original anti- rotation pin design

Impact of radial retention pin liberation

pin design Impact of radial retention pin liberation Typical damage from radial retention pin liberation –
Typical damage from radial retention pin liberation – more severe than anti- rotation pin liberation
Typical damage from radial retention
pin liberation – more severe than anti-
rotation pin liberation

47 /

CFM Proprietary Information subject to restrictions on the cover

– more severe than anti- rotation pin liberation 47 / CFM Proprietary Information subject to restrictions
– more severe than anti- rotation pin liberation 47 / CFM Proprietary Information subject to restrictions
– more severe than anti- rotation pin liberation 47 / CFM Proprietary Information subject to restrictions

VSV System Improvements

VSV System Improvements New system introduced • July 2014 production intro • SB 72-0906 (5B), 72-0958

New system introduced

July 2014 production intro

SB 72-0906 (5B), 72-0958 (7B) & 72-

0763 (5C) cat 7

Improvements

 

1. Brazed End Blocks Replace Anti-rotation Pin

 

Addresses anti-rotation pin liberations

Reduced seal sliding and wear

 

2. Shroud Hard Anodizing

 

Reduced wear on all surfaces

 

3. Increased Aft Shroud Clearance

 

• 0.070” additional clearance

Increased time to 4-9 spool contact

 

4. Increased Forward Shroud Clearance

 

• 0.030” additional clearance

Increased time to shroud to blade platform contact

48

/

CFM Proprietary Information subject to restrictions on the cover

2. Hard Anodizing

subject to restrictions on the cover 2. Hard Anodizing 1. Seal End Blocks 4. Increased Fwd
subject to restrictions on the cover 2. Hard Anodizing 1. Seal End Blocks 4. Increased Fwd

1. Seal End Blocks

4. Increased Fwd Shroud Clearance

.030”

.070”
.070”

3. Increased Aft Shroud Clearance

2. Hard Anodizing 1. Seal End Blocks 4. Increased Fwd Shroud Clearance .030” .070” 3. Increased
2. Hard Anodizing 1. Seal End Blocks 4. Increased Fwd Shroud Clearance .030” .070” 3. Increased
2. Hard Anodizing 1. Seal End Blocks 4. Increased Fwd Shroud Clearance .030” .070” 3. Increased

On-wing Recommendations

On-wing Recommendations • No on-wing action recommended for fleet • Limited number of anti-rotation pin liberations

No on-wing action recommended for fleet

Limited number of anti-rotation pin liberations have resulted in recoverable engine stall

Majority of liberations found during routine shop visit

• No engines have liberated both 3 and 9 o’clock pins which would likely result

in radial retention pin liberation

Perform MPD inspection of HPC blades

CFM56-5B SB 72-0727 (cat 2) recommends 10,000 cycles initial BSI with repeat at 5,000 cycles re-inspect interval

CFM56-7B MPD recommends 6,600 cycles or 15,000 hours initial and repeat

interval

CFM56-5C MPD does not recommend specific HPC blade inspection interval but many operators have incorporated a periodic inspection plan

If HPC blade damage found in stages 4-9 perform rotor to stator contact inspection to verify presence of stage 3 anti-rotation pins

Perform Rotor to stator contact inspection per SB 72-0553 (5B), 72-

0515 (7B) or 72-0427 (5C) when applicable

49 /

CFM Proprietary Information subject to restrictions on the cover

(5B), 72- 0515 (7B) or 72-0427 (5C) when applicable 49 / CFM Proprietary Information subject to
(5B), 72- 0515 (7B) or 72-0427 (5C) when applicable 49 / CFM Proprietary Information subject to
(5B), 72- 0515 (7B) or 72-0427 (5C) when applicable 49 / CFM Proprietary Information subject to

2014 ISC Recommendations

2014 ISC Recommendations 50 / CFM Proprietary Information subject to restrictions on the cover
2014 ISC Recommendations 50 / CFM Proprietary Information subject to restrictions on the cover

50 /

CFM Proprietary Information subject to restrictions on the cover

2014 ISC Recommendations 50 / CFM Proprietary Information subject to restrictions on the cover
2014 ISC Recommendations 50 / CFM Proprietary Information subject to restrictions on the cover
2014 ISC Recommendations 50 / CFM Proprietary Information subject to restrictions on the cover

Shop Recommendations

Shop Recommendations • Incorporate new VSV system replacing anti-rotation pin with brazed end block • SB

Incorporate new VSV system replacing anti-rotation pin with brazed end block

SB 72-0906 (5B), 72-0958 (7B) & 72-0763 (5C) cat 7

If system not replaced, measure shroud slot width per ESM 72-32-07,

Inspection 001

Following inspection criteria being added to ESM

Wear on dimension F Stage 3

Minimum Serviceable Limit: --

Maximum Serviceable Limit: 0.230 inch (5,84 mm)

Maximum Repairable Limit: Not repairable

Repair Method: --

Repairable Limit: Not repairable • Repair Method: -- 51 / CFM Proprietary Information subject to restrictions

51 /

CFM Proprietary Information subject to restrictions on the cover

Limit: Not repairable • Repair Method: -- 51 / CFM Proprietary Information subject to restrictions on
Limit: Not repairable • Repair Method: -- 51 / CFM Proprietary Information subject to restrictions on
Limit: Not repairable • Repair Method: -- 51 / CFM Proprietary Information subject to restrictions on